Method and material for repairing of cracks in pavement and other surfaces

ABSTRACT

The present invention relates to a method of repairing cracks and holes in pavement surfaces. This method involves filling a crack or hole in a paved surface with a flexible crack filler mix until the mix fills up the site and overlaps the edges of the aperture to a predetermined amount. Thereafter, the method includes the step of applying a zig-zag shaped mesh tape on top of the filled crack. The extra layer of a crack filler mix gets applied on top the zig-zag shaped mesh tape. Also disclosed is a material for repairing a crack in a paved surface.

CLAIM OF PRIORITY

This application claims priority under 35 USC Section 119(a) from U.S. Provisional Application No. 61/356,363 filed Jun. 18, 2010. The above mentioned application is hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention is directed to a method and system for repairing cracks or holes in a paved surface.

Various methods for repairing cracks and holes in paved surfaces, concrete or asphalt roadways, driveways and recreational surfaces, such as tennis courts, outdoor basketball courts, volleyball courts and running tracks generally involve cleaning the crack of loose debris and then filling the crack with a crack filler material that hardens to a solid state, forming a smooth surface with the surrounding pavement surface. This is more economical than re-paving the entire section of pavement which may contain only one or a few cracks.

However, such crack repair method is considered a temporary repair since progressive maintenance must be applied because of continued crack enlargement under changing environmental conditions, including temperature and moisture fluctuations. Repaired cracks continue to expand since current repair methods do not address and alleviate the stresses that cause crack formation and movement.

One attempt to lengthen and extend the repair times between maintaining a repaired crack in a pavement, or other surface, is applying a strong surface such as an adhesive fiberglass sheet above the repaired crack. However, the fiberglass sheet, while presenting a solid, hard surface, is also susceptible to tears and cracks caused by movement and/or enlargement of the underlying repaired crack.

In further attempts to address this problem, other crack repair methods have been developed which follow a so-called “slip-sheet” principle. In these methods, after the crack is cleaned and filled with a crack filler to the surface level of the surrounding pavement or recreational surface, a slip-sheet is affixed to the top surface of the crack filler. One layer of sheet material, was applied over the slip-sheet and adhered at peripheral edges to the surrounding pavement or recreational surface. This isolates the sheet from the slip-sheet thereby enabling the slip-sheet to move with crack movement or enlargement without generating stresses in the outermost sheet which could tear or rip the outer sheet.

Several of these previously devised crack repair methods make use of adhesive-back tape, such as “duct tape”, which has a non-adhering polyethylene outer surface. U.S. Pat. No. 6,450,729—Pavement surface crack repair method by Daniel C. Clapp describes the crack repair method utilizing two 2-inch wide duct tape strips which are applied side edge to side edge over a cleaned and filled crack. The plastic backing of the duct tape prevents adherence to overlaying sheets. Clapp applied an adhesive layer over and beyond the duct tape for a predetermined width outside of the outer periphery of the tape strips before applying a single 9-inch wide sheet of stretchable fabric. Another wider area of adhesive is applied over the stretchable fabric sheet for adhering a second, wider stretchable fabric sheet of approximately twice the width as the first fabric sheet. After adhesive is applied to the edges of the outermost stretchable fabric sheet, two 6-inch wide strips of fiberglass sheet were applied to the side edges of the outermost stretchable sheet. Early slip-sheet methods are disclosed in U.S. Pat. Nos. 3,663,350 and 3,932,051.

Another method of crack repair using a “slip-sheet” utilizes a tape material with a shiny outer surface, prepared from polyethylene, Mylar, Teflon or other such materials, as disclosed in U.S. Pat. No. 6,450,729. An adhesive tape, such as “duct tape”, which has a non-adhering polyethylene top surface, is one example of a “slip-sheet” of this invention.

In an alternative method, which is disclosed in U.S. Pat. No. 5,464,304, a liquid waterproofing material is applied directly over the filled crack. This liquid waterproofing material dries with a non-adhering top surface that isolates the crack from additional materials placed over the non-adhering surface. Over this non-adhering surface are secured several fabric layers fastened together with acrylic binders. The key step in this process,however, is the crack isolation step produced by the application of the liquid waterproofing material to the recreational court.

The process of U.S. Pat. No. 5,464,304 is similar to that of U.S. Pat. No. 6,450,729 in that both rely on the application of a non-adhering material to the recreational court or surface over which other materials are placed. Many different types of materials and adhesives may be applied over the slip-sheet or other non-adhering surface to complete the crack repair. More advanced crack repair method provides a “slip-sheet” between the filled crack and an overlaying stretchable fabric layer wherein the fabric layer is capable of stretching under stresses induced by crack growth and reformation without rupturing the crack repair patch.

While the described prior crack repair methods significantly lengthens the time between maintenance to a repaired crack, these methods still experience failures due to and caused by crack reformation. Another very significant problem is related to a crack shape. The crack shape does not normally allow the application of straight, uniformly shaped, strips of overlaying material. Custom shaped pieces of material, to follow the crack must be individually cut which makes this method somewhat haphazard and time consuming.

Thus, it would be desirable to provide an improved pavement crack repair method which significantly reduces the reformation of repaired cracks in pavement or other surfaces. It would also be desirable to provide an improved crack repair method which allows to repair cracks with any shape.

BRIEF SUMMARY OF THE INVENTION

The shortcomings and failings of the previously mentioned methods as well as addressing other needs such as cost, simplicity, ease-of-use and durability have been satisfied by the method of the present invention being a method for the sealing of cracks in pavement surfaces and roadways that utilizes a zigzag shaped “mesh tape” material

More specifically, the method of the present invention includes filling a crack or hole in a paved surface with a flexible crack filler mix until the mix fills up the site and overlaps the edges of the aperture to a predetermined amount. Thereafter, the method includes the step of applying a zig-zag shaped mesh tape on top of the filled crack. The extra layer of a crack filler mix gets applied on top the zig-zag shaped mesh tape.Without being bound to any particular theory or mechanism, it is believed that sealing properties of process are enhanced by use of the zig-zag shaped mesh tape.

It is another aspect of the invention that the zig-zag shaped mesh tape material can consist of multiple mesh elements loosely connected to each other.Mesh elements could be rotated against each other to follow any shape of the pavement cracking when applied on top of it.

It is another aspect of this invention that the zig-zag shaped mesh tape material can consist of multiple elements each having heat-melt adhesive applied to the bottom side. The adhesive gets activated when a heat gun is applied on top of the tape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overall view of invention when zig-zag shaped mesh tape is created from rectangular elements.

FIG. 2 is an overall view of invention when zig-zag shaped mesh tape is created from oval elements.

FIG. 3 is an overall view of alternative embodiment.

FIG. 4 is a diagram of the invented method of a pavement crack repairs.

FIG. 5 is a schematic diagram of mesh element movement against each other.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 4 depicts a crack 406 in a pavement 401.The crack 406 is about two inches in depth and ¼ inch wide. The method of the present invention is preferably used with cracks of such a depth, in various types of bituminous pavements, or cement concrete pavements. However, the scope of the invention is not confined to repair sites of such a depth and width.

In accordance with the method of the present invention, the crack 406 in the pavement is filled with a flexible crack filler. The term “crack filler” as used herein shall include petroleum emulsions, asphalt emulsions or modifications to such emulsion, acrylic emulsions,rubberized asphalt and epoxy mixtures, heat melt fillers.

A suitable flexible crack filler that can be used in conjunction with this invention is a product sold under the trademark “Latex-ite Blacktop Crack Filler” by Dalton Enterprises, Inc. of Cheshire, Conn. It is preferred that the crack filler used in the process of the present invention has a viscosity range, as will be understood by those skilled in the art on asphalt emulsions' residue by ASTM Standard D-244 of 10 to 3,000 poises, at 60 degrees 50 C. (Celsius). (With respect to the CRF product, conversion of cSt (Centistokes) viscosity of the CRF product at 60 degrees C. to poises is about 1 poise=100 cSt).

The crack 406 is filled with the crack filler until it substantially overlaps onto the pavement surface 403 on each side of the aperture. For example, but without being bound by the example, the overlap may measure approximately ⅛to ¼ inches or further, as desired in a particular application. The overlapping portions of crack filler are illustrated in the figure with reference characters 403.

After the crack has been filled and overlaps the crack 406 in the pavement surface, the repairer will then cover the crack with this invention, a zigzag shaped mesh tape. The term “zigzag shaped mesh tape” as used herein shall include multiple mesh elements, loosely connected to each other according to the FIG. 1.

Preferably mesh elements are loosely connected to each other by, but not limited, to stitching. In certain circumstances, as will be understood by those skilled in the art, various techniques will be used to connect mesh elements, such as by use of plastic barbs, fasteners, applying heat source for a short time to connection spots and in-line die cutting. FIG. 3 depicts the Zigzag shaped mesh tape created by in-line die cutting.

In preferred embodiment of this invention mesh elements are made out of the vinyl coated fiberglass. Such materials are available commercially. A suitable material is sold under the trademark “Phifer Charcoal Fiberglass Screen” by PHIFER Incorporated of Tuscaloosa, Ala. Other types of material can be used, such as different types of plastics, fiberglass, polymer covered fibreglass mesh, thin metal wire and woven materials.

Zigzag shaped mesh tape elements can be rectangular, triangular, oval, or might have other shapes. For example, but without being bound by the example, zigzag mesh element have oval shape as it is shown on FIG. 2. It is desirable to have several width sizes of the tape to cover cracks of different widths, each performing the same functionality as described and achieving the same result. For example, but without being bound by the example, the base standard size of a zigzag mesh element is 2.5 in. wide and 3 in. long.

In preferred embodiment of this invention zigzag shaped mesh tape is packaged in a 10 foot long roll with 3″ paper core. Other methods of packaging can be used, such as folding of the zig-zag shaped mesh tape. 

1. A method of repairing a crack in a pavement surface comprising the steps of: cleaning the crack of debris; filling the crack with first portion of “crack filler” material that is allowed to harden to a solid state; applying an additional portion of “crack filler” material to the sides of said opening; applying a zigzag shaped tape over the filled crack and side portion of the filler material; the zigzag shaped tape being formed from loosely connected mesh segments that will follow the natural line of the crack; applying a second portion of “crack filler” material over the laid zigzag shaped tape and for a distance beyond side edges of said tape; where the said distance is at least 1/32 inch; wherein said hardened “crack filler” material remains reasonably flexible and stretchable under temperatures between −45 C and +60 C. This allows and facilitates contraction and expansion between 0.3% and 8% of total width of said crack
 2. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the said “crack filler” material is water based mix
 3. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the said “crack filler” material is a petroleum emulsion
 4. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the said “crack filler” material is a polyepoxide thermosetting polymer
 5. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the said “crack filler” material is a hot-melt material, such as a liquefied rubber based compound as used by most driveway repair contracting companies.
 6. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the said “crack filler” material of said first portion is different type from said “crack filler” material of said second portion
 7. A method of repairing a crack in a pavement surfaces recited in claim 1, wherein the additional portion of said “crack filler” material is different type from said “crack filler” material of said first portion
 8. A material for crack repairs comprising a plurality of mesh segments connected in a chain by connectors; wherein said segments are in the same plane; wherein said connectors allow at least 10 degree rotation of said segments in the same plane against each other; wherein said mesh sizes are between 5×5 and 30×30 of Tyler scale, said mesh is made out of a vinyl coated fiberglass wire; said segments have minimum length of ⅙ in. and maximum length of 5 in.; said segments have a rectangular shape; said connectors are formed by stitching; said wire has gage from BWG31 to BWG38
 9. A material for crack repairs recited in claim 8 wherein said mesh is made out of stainless steel wire
 10. A material for crack repairs recited in claim 8 wherein said mesh is made out of aluminum wire
 11. A material for crack repairs recited in claim 8 wherein said mesh is made out of iron wire
 12. A material for crack repairs recited in claim 8 wherein said mesh is made out of polymer wire
 13. A material for crack repairs recited in claim 8 wherein said connector is provided by stitching
 14. A material for crack repairs recited in claim 8 wherein said connector is provided by riveting
 15. A material for crack repairs recited in claim 8 wherein said connector is provided by spot melting
 16. A material for crack repairs recited in claim 8 wherein said connector is provided by applying of a barb
 17. A material for crack repairs recited in claim 8 wherein said plurality of mesh segments is created by rotary die-cutting of a continues mesh tape.
 18. A material for crack repairs recited in claim 8 wherein said plurality of mesh segments is created by stamping of a continues mesh tape
 19. A material for crack repairs recited in claim 8 wherein said plurality of mesh segments is wound on the roll
 20. A material for crack repairs recited in claim 8 wherein said plurality of mesh segments is folded to a stack 